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FIBERWEB PLC
Fiberweb is the leading pure-play nonwovens producer in the world, with factories
in North and South America, Europe and Asia.OVERVIEW
Fiberweb, known until recently as BBA Fiberweb, a division of the UK’s BBA
Group, was created in the 1990s from the purchase and consolidation of a series of
The roll call of the largest acquired companies, and their years of purchase,
includes Reemay, 1989; Terram, early 1990s; Fiberweb, 1995; Corovin, 1996;
Korma, and Bidim, 1997; Veratec, 1998; AQF Technologies, and Snow Filtration
Co., 2000; Superior Nonwovens, and Technofibra, 2003; and Tenotex, 2004.
A restructuring program was begun by CEO Daniel Dayan, shortly after he
was hired in June 2005. The program, which continues, closed the Canada
PERSONNEL
spunmelting factory, shut multiple lines in the USA and Europe, and ended the
joint venture spunbonding factory in Thailand. New lines are going into Sweden,
Italy and China, while existing equipment was moved to Germany, Mexico and
In November 2006, the BBA Group, after deciding to concentrate on its
aviation services business, spun off the nonwovens division, and the newly
independent company listed itself on the London Stock Exchange under the name
Fiberweb reported 2006 consolidated operating profit of £27.5 million, down
43% compared with 2005, on revenue of £584.7 million, down more than 3%compared with 2005. For the year, the company had a loss of nearly £70 million, andnet debt of £165 million.
The company divides its business into two segments,
In April 2006, two lines at the Washougal, Washington,
hygiene, and industrial. Last year, the hygiene division
factory, a SMS and a spunbond, were shut, and 60 employees
reported an operating profit of £14.5 million, down 50%
were laid off. At the same time, three lines at the
compared with 2005, on sales of £381.5 million, down nearly
Simpsonville, South Carolina, plant were slated to stop: a
spunbonding machine, which was no longer competitive; a
The industrial segment reported operating profit of
spunmelting machine, following the loss of a Cardinal Health
£14.7 million, down 31% compared with the previous year,
contract; and a pilot line. The move affected 100 employees.
on sales of £203.2 million, up 5% on the year.
By the end of the year, one of the two Terram lines in
Geographically, 47% of total sales came from North
Pontypool, UK, was slated to shut, cutting about 50 jobs. At
America, 46% came from Europe, and the remainder came
about the same time, workers at the Bethune, South
Carolina, factory were notified that two of three aging
The company blamed its 2006 results on restructuring
thermalbonding lines would be stopped. The 40-year-old
charges, raw materials and utilities costs, a power outage at
lines produced Novonette medical and wipes fabric. The
the Old Hickory, Tennessee, plant, which cost £2 million,
new costs associated with the demerger from the BBA
Also in late 2006, the company sold to its partners for
$10.3 million in cash its 50% ownership in CNC
Customers. Procter & Gamble Co. is Fiberweb’s largest
International Co. Ltd., a hygiene spunmelting operation in
customer. It accounted for about a third of sales in 2005.
Thailand with Reifenhauser equipment: a 3.2-meter-wide
Current contracts between Fiberweb subsidiaries and P&G
SMS and a 4.2-meter-wide SMMS line. Free of its partners,
Fiberweb may launch a new spunmelting facility in Asia.
• More than two-year-long worldwide contract, begun
Meanwhile, the company is still looking to sell its
in 2007, to supply 250,000 tonnes of spunmelted
cotton-bleaching business in Griswoldville, Massachusetts.
fabrics. The deal is worth more than £330 million.
Finally, as the company noted in its initial public offering
• Five-year agreement, begun Jan. 1, 2007, for Korma to
prospectus: “Single line sites in Fiberweb’s North American
supply airlaid core and STC materials.
hygiene business may not continue to be competitive in the
• Three-year agreement, begun Jan. 1, 2006, for
medium-term given their lack of scale, and therefore further
Reemay to supply disposable dryer sheets.
site rationalization may be necessary.”
• Extended Simpsonville’s baby wipes fabric agreement
As Fiberweb stopped its most uncompetitive
equipment, it purchased new machinery and promises to add
• Extended Bethune’s baby wipes fabric agreement
In 2006, the company bought a Neumag M&J airlaid line
• Extended China airlaid agreement by three years.
for its Korma plant in Italy. The line, to start in early 2007, will
• Extended research and development programs.
produce acquisition-distribution layers for P&G. Also last year,
Current contracts with other companies include:
the company purchased a Reicofil 4 5.2-meter wide SSMMS
• Three-year agreement, begun Jan. 10, 2006, for
line for its Norrkoping, Sweden, factory. The machine has
Reemay to supply private label housewrap to Johns
annual capacity of 20,000 tonnes. The project cost is $25
million. The line will start in the first half of this year.
• An agreement of unstated length, begun Aug. 1, 2005,
The purchase of a China-made 2.1-meter-wide drum-
for Simpsonville to supply bleached-cotton blend
technology airlaid line was announced in early 2007. It is due
products to Amantea Nonwovens LLC for resale to
to be started in the company’s Tianjin, China, factory in early
2008. The 10,000 tonne line will be built by Shanghai
• Extended for three years Simpsonville’s agreement
Expansion Industries. The project cost was $12 million.
with Tyco Healthcare, worth about $6.5 million annually.
In April 2006, the company purchased for £2.8 million
Some of Fiberweb’s other large customers include
the privately held German roofing business Blowitex GmbH.
Kimberly-Clark, SCA, Hartmann, Huish, Huttig and
Fiberweb officials have announced that they are
considering adding capacity worldwide, but no additionaldetails have been released. However, in last year’s full-year
RESTRUCTURING
financial report, the company noted that “capital investment
Fiberweb has completed a variety of restructuring
will continue at the high level seen in 2006.”
measures, and there are more to come.
The company is also reviewing its spunlaced wipes
In 2005, the two spunmelting line factory in Canada was
business in Europe and the USA. Commodity wipes fabric
shut, and the facility’s 79 employees were laid off. One of the
prices have been falling on both continents for some time,
lines was shipped to the Mexico factory, and the other was
and Fiberweb officials are not happy with the business.
sent to the Berlin, Germany, factory.
Solutions include exiting the market.AMERICAS OPERATIONS
to supply absorbent core fabric to Procter & Gamble Co. for
Bethune, SC. The facility houses a four-year-old Rieter
use in domestic femcare products, as well as wet wipes and
Perfojet spunlacing line to produce wipes fabric for Procter
& Gamble. It also houses a smaller spunlacing line. At least
The $68 million plant was constructed in Tianjin, just
two of the facility’s three Novonette thermalbonding lines
outside Beijing. It has an annual capacity of about 16,000
will be shut this year after a customer ended its medical
tonnes. It is a 2.7-meter-wide line incorporating forming
products contract, sending the business to China. The third
heads supplied by M&J Fibretech. The line is capable of both
latex bonding and thermalbonding. The plant also has
Grey Court, SC. This facility houses a single Kobelco SS
festooning, slitting, and packaging capability.
line. Fiberweb acquired the polyester spunbonding plant in
In early 2008, a China-made Shanghai Expansion
2003 from Superior Nonwovens in early 2003. It is now part
Industries airlaid line will start up. The line has an annual
of the Reemay business based in Old Hickory, Tennessee.
capacity of about 10,000 tonnes. The project was slated to
Simpsonville, SC. This facility has significantly changed
in the past year. Once the site of the company’s latestspunmelting technology, the factory no longer has
EUROPEAN OPERATIONS
spunmelting capacity. Today, the facility houses a high-speed
France. The company’s operation in France is located at
carding line and one other production line. In 1999, a
Biesheim in the northeast of the country. The facility’s main
proprietary Korma absorbent core composite line was
product is S-Tex fabric. The first proprietary S-Tex
coextrusion spunbonded line started in 1996, followed by
Old Hickory, TN. This is one of Fiberweb’s oldest
another in late 2000. The S-Tex fabric is primarily used for
businesses, acquired from DuPont for about $65 million. The
purchase included the US-based Typar spunbonded
Germany. Fiberweb has four wholly owned facilities in
polypropylene and the worldwide Reemay spunbonded
Germany: Corovin, Linotec, Fiberweb Berlin, and Blowitex,
polyester businesses. The sale included manufacturing
facilities for the products at Old Hickory, as well as
At one time, the Corovin site had at least seven
associated patents, technologies, and inventories. The sale
spunbonding lines. Today, the facility produces hygiene
did not include DuPont’s manufacturing facility for Typar in
materials on two Reicofil 3 SMMS lines with an annual
Luxembourg. Snow Filtration, an Ohio filter converting
business, was moved to the site in 2004. The factory
Linotec Development GmbH was established in 1997 as
manufactures filter, housewrap, geotextile and dryer sheet
a joint venture by Corovin and machinery manufacturer
Reifenhauser GmbH. Linotec is now wholly owned by
Washougal, WA. This facility houses a single SSS line
Fiberweb. The business developed an ultra-lightweight
that produces specialty diaper materials, including stretch
spunbonded production process that produces uniform
fabrics, a product that was transferred from Simpsonville
fabrics with basis weights as low as 8 gsm, and widths up to
following last year’s shutdown of the spunbonding line there.
5.4 meters, using a proprietary stretching process. The
A new calendering system was also installed. The new
company also manufactures standard PE/PP spunbonded
business followed last year’s shutdown of two aging Lurgi
fabrics on its double-beamed lines, and it can laminate
spunbonded fabrics with polyethylene film to create
Green Bay, WI. The factory operates a single
breathable Linopore brand fabrics. Major applications
resinbonding line, producing feminine hygiene acquisition-
include hygiene, medical, and industrial.
Fiberweb Berlin is the largest facility today. It houses
Fiberweb Mexico. The factory operates two SMS lines
four spunbonding lines, including a line moved from Toronto,
for hygiene products. The first line was started in 1996. The
Canada, which produces roofing fabrics.
second line was moved last year from the former Toronto,
The Blowitex business produces residential roofing
materials. The business’ capacity is unknown.
Fiberweb South America. The Brazilian site produces
Italy. Fiberweb has five production facilities in Italy,
spunbonded, needled polyester-based geotextiles, roofing
including the factories purchased from Tenotex in 2004 and
and apparel fabrics. A carding line was added last year, using
Technofibra in 2003. Fiberweb’s production facility at
parts from a Simpsonville line, to serve the footwear
Trezzano Rosa houses four lines. The newest, started in
industry. The project cost $4 million.
Fiberweb’s absorbent core manufacturer, Korma SpA,
CHINA OPERATIONS
manufactures laminated absorbent core products for Procter
In early 2001, BBA started up its first wholly owned
& Gamble. In early 2007, a new Neumag airlaid line is due to
production facility in Asia, a greenfield airlaid plant in China
Technofibra has two spunlacing lines and a
Design Concepts GmbH, 50%; Saudi German Nonwovens
Products Co., 15%; and Cordustex (Pty) Ltd., 10%.
The two Tenotex facilities together house three
The most significant production venture is believed to
through-air bonding lines, three thermalbonding lines, two
be the Saudi German business, which operates three
spunmelting lines, a resinbonding line and additional
spunmelting lines with a total annual capacity of less than
equipment, mostly serving the hygiene market.
20,000 tonnes. The lines supply the hygiene and medical
Spain. The Tenotex business also includes a factory in
Spain. It houses a high-speed thermalbonding line and a two-card Fleissner spunlacing line with pulp capability.BUSINESS OUTLOOK
Sweden. Fiberweb is installing a Reicofil 4 SSMMS line
Following a worldwide capacity restructuring and
at this asset. The line will serve the hygiene market. The
modernization program, Fiberweb promises more,
new line was originally said to increase the facility’s capacity
unspecified, capital upgrades in 2007. At the same time, the
by 50%, but this year that figure was dropped to 15%. It is
company is focusing on profitable and growing product
not known what other equipment still functions at the plant.
On the industrial side, it is seeking to expand sales of
Typar and Reemay construction and filtration products,
geotextiles and construction fabrics markets. Last year, one
maintain its “leading share” in fabric softener and graphic
of the site’s two lines was shut, and the remaining line was
arts wipes, and commercialize digital printer wipes and
given a £1 million upgrade. The improved line will be able to
make fabric for railway beds and military applications.
On the hygiene side, the company continues to review
its future in wipes, while it continues to develop elastic and
JOINT VENTURES/INVESTMENTS
other new materials. Finally, it intends to strengthen its
Fiberweb participates in the following five joint
relationship with its most important customer, Procter &
ventures, including ownership percentages: Coratech
Gamble, and develop new customers while it “reduce[s]
GmbH, 25.1%; Coronor Composites GmbH, 50%; Advanced
Fiberweb PLC Production (Nonwovens Markets Estimates)Manufacturing LocationEquipment/technology Fibers/resinsFabric properties Capacity
BrazilTel.: (+55) 12 3946 4645Fax: (+55) 12 3922 0551
Fiberweb (China) Airlaid 1 M&J airlaid line, thermal ,
Tianjin 300457 ChinaTel.: (+86) 22 2532 9333
(EPS) airlaid line(To start in early 2008)
Tel.: (+33) 389 72 4700Fax: (+33) 389 72 8982
Daimlerstrasse 3D 06449 AscherslebenGermany
D 31201 PeineGermanyTel.: (+49) 5171 408 0Fax: (+49) 5171 408 999
ItalyTel.: (+39) 0331 836 01Fax: (+39) 0331 836 060
Fiberweb PLC Production (Nonwovens Markets Estimates)Manufacturing LocationEquipment/technology Fibers/resinsFabric properties Capacity
ItalyTel.: (+39) 039 6284 71Fax: (+39) 039 62847700
7,400 tonnes,including thesecondItalian plant
9,700 tonnes,510 millionsquaremeters,including thesecond Italianplant
Fiberweb Tenotex SpA 1 through air bond line with
GTOMexicoTel.: (+52) 42 110 900Fax: (+52) 42 110 999
Fiberweb PLC Production (Nonwovens Markets Estimates)Manufacturing LocationEquipment/technology Fibers/resinsFabric properties Capacity
Ctra. de VillenaOntenienteE 03460 Benejama(Alicante)SpainTel.: (+34) 965 822 331
S 60119 NorrköpingSwedenTel.: (+46) 11 24 4400Fax: (+46) 11 640 75
PontypoolGwent NP4 0YRUKTel.: (+44) 1495 767 444Fax: (+44) 1495 762 393
Gray Court, SC 29645USATel.: (+1) 864 876 5040Fax: (+1) 864 876 4315(Formerly SuperiorNonwovens)
USATel.: (+1) 864 967 5600Fax: (+1) 864 967 5695
Fiberweb PLC Group Production (Nonwovens Markets Estimates)Manufacturing LocationEquipment/technology Fibers/resinsFabric properties Capacity
Tel.: (+1) 615 847 7000Fax: (+1) 615 847 7068
USATel.: (+1) 360 835 8787Fax: (+1) 360 835 2546
Green Bay, WI 54304USATel.: (+1) 920 336 0222
GLOBAL NONWOVENS COMPANY PROFILESEach company profile includes:Companies profiled:
• Production Capability - Charts detail manufacturing lines, equip
ment, fibers/resins, widths, capacities, products and markets.
• Technology Overview - Who's using what technology to manufacture
their roll goods, plus production figures by technology. We've included
charts detailing major technologies for each company.
• Sales Volume - Complete revenue data.
• History - How the company was formed and how it evolved in the
nonwovens industry; plus details on the latest mergers & acquisitions.
• Raw Material Demand - Who's using which raw materials for their
•E.I. Du Pont De Nemours & Co. •Polyfelt GMBH
products. Subsidiaries/Joint Ventures - What markets each company
serves and where those markets are located.
• Personnel Listings - The ideal industry contact list, including name,
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ABSTRACT: The relation between indices of neonatal iron status and individualdifferences in neonatal temperament were investigated in a sample of 148 low-income Peruvian women and their newborn infants. Using cord blood, at birth weobtained measures of neonatal ferritin, serum iron, and hemoglobin. While neonateswere still in the hospital, their behavior during a structured anthropometry exami-